JP5961699B2 - ハニカム構造体及びその製造方法 - Google Patents
ハニカム構造体及びその製造方法 Download PDFInfo
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- JP5961699B2 JP5961699B2 JP2014545501A JP2014545501A JP5961699B2 JP 5961699 B2 JP5961699 B2 JP 5961699B2 JP 2014545501 A JP2014545501 A JP 2014545501A JP 2014545501 A JP2014545501 A JP 2014545501A JP 5961699 B2 JP5961699 B2 JP 5961699B2
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- honeycomb structure
- honeycomb
- manufacturing
- alumina
- substance
- Prior art date
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- 238000004519 manufacturing process Methods 0.000 title claims description 25
- 239000011230 binding agent Substances 0.000 claims description 47
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 45
- 238000000465 moulding Methods 0.000 claims description 43
- 239000000126 substance Substances 0.000 claims description 42
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 40
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 38
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 claims description 36
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 claims description 34
- 239000002131 composite material Substances 0.000 claims description 30
- 239000000463 material Substances 0.000 claims description 30
- 238000000034 method Methods 0.000 claims description 28
- 239000012784 inorganic fiber Substances 0.000 claims description 25
- 239000000377 silicon dioxide Substances 0.000 claims description 19
- QGZKDVFQNNGYKY-UHFFFAOYSA-N ammonia Natural products N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 claims description 18
- 239000011521 glass Substances 0.000 claims description 12
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 claims description 11
- HZAXFHJVJLSVMW-UHFFFAOYSA-N 2-Aminoethan-1-ol Chemical compound NCCO HZAXFHJVJLSVMW-UHFFFAOYSA-N 0.000 claims description 10
- UNTBPXHCXVWYOI-UHFFFAOYSA-O azanium;oxido(dioxo)vanadium Chemical compound [NH4+].[O-][V](=O)=O UNTBPXHCXVWYOI-UHFFFAOYSA-O 0.000 claims description 10
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 10
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 10
- UEEJHVSXFDXPFK-UHFFFAOYSA-N N-dimethylaminoethanol Chemical compound CN(C)CCO UEEJHVSXFDXPFK-UHFFFAOYSA-N 0.000 claims description 9
- 229960002887 deanol Drugs 0.000 claims description 9
- ZBCBWPMODOFKDW-UHFFFAOYSA-N diethanolamine Chemical compound OCCNCCO ZBCBWPMODOFKDW-UHFFFAOYSA-N 0.000 claims description 9
- 238000004898 kneading Methods 0.000 claims description 8
- 238000002156 mixing Methods 0.000 claims description 8
- 239000002994 raw material Substances 0.000 claims description 7
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 claims description 7
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical group [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 6
- OJMOMXZKOWKUTA-UHFFFAOYSA-N aluminum;borate Chemical compound [Al+3].[O-]B([O-])[O-] OJMOMXZKOWKUTA-UHFFFAOYSA-N 0.000 claims description 6
- 229910001593 boehmite Inorganic materials 0.000 claims description 6
- NJLLQSBAHIKGKF-UHFFFAOYSA-N dipotassium dioxido(oxo)titanium Chemical compound [K+].[K+].[O-][Ti]([O-])=O NJLLQSBAHIKGKF-UHFFFAOYSA-N 0.000 claims description 6
- 238000010304 firing Methods 0.000 claims description 6
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 claims description 6
- 229910052720 vanadium Inorganic materials 0.000 claims description 6
- 238000009835 boiling Methods 0.000 claims description 5
- 210000004027 cell Anatomy 0.000 claims description 5
- 210000002421 cell wall Anatomy 0.000 claims description 5
- 239000010456 wollastonite Substances 0.000 claims description 5
- 229910052882 wollastonite Inorganic materials 0.000 claims description 5
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 claims description 4
- 239000004113 Sepiolite Substances 0.000 claims description 3
- 229960000892 attapulgite Drugs 0.000 claims description 3
- 239000000440 bentonite Substances 0.000 claims description 3
- 229910000278 bentonite Inorganic materials 0.000 claims description 3
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 claims description 3
- YGANSGVIUGARFR-UHFFFAOYSA-N dipotassium dioxosilane oxo(oxoalumanyloxy)alumane oxygen(2-) Chemical compound [O--].[K+].[K+].O=[Si]=O.O=[Al]O[Al]=O YGANSGVIUGARFR-UHFFFAOYSA-N 0.000 claims description 3
- 229910052627 muscovite Inorganic materials 0.000 claims description 3
- 229910052625 palygorskite Inorganic materials 0.000 claims description 3
- 235000019353 potassium silicate Nutrition 0.000 claims description 3
- 229910052624 sepiolite Inorganic materials 0.000 claims description 3
- 235000019355 sepiolite Nutrition 0.000 claims description 3
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 3
- 239000007787 solid Substances 0.000 claims description 3
- 239000011787 zinc oxide Substances 0.000 claims description 3
- 229910052751 metal Inorganic materials 0.000 description 38
- 239000002184 metal Substances 0.000 description 38
- 230000007797 corrosion Effects 0.000 description 22
- 238000005260 corrosion Methods 0.000 description 22
- 239000010410 layer Substances 0.000 description 19
- 230000002093 peripheral effect Effects 0.000 description 18
- 238000010586 diagram Methods 0.000 description 17
- 239000003054 catalyst Substances 0.000 description 15
- 239000000835 fiber Substances 0.000 description 15
- 239000007789 gas Substances 0.000 description 15
- 239000002245 particle Substances 0.000 description 14
- 239000012790 adhesive layer Substances 0.000 description 12
- 238000000746 purification Methods 0.000 description 12
- TXKMVPPZCYKFAC-UHFFFAOYSA-N disulfur monoxide Inorganic materials O=S=S TXKMVPPZCYKFAC-UHFFFAOYSA-N 0.000 description 11
- XTQHKBHJIVJGKJ-UHFFFAOYSA-N sulfur monoxide Chemical compound S=O XTQHKBHJIVJGKJ-UHFFFAOYSA-N 0.000 description 11
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 11
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- 229910010413 TiO 2 Inorganic materials 0.000 description 7
- XHCLAFWTIXFWPH-UHFFFAOYSA-N [O-2].[O-2].[O-2].[O-2].[O-2].[V+5].[V+5] Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[V+5].[V+5] XHCLAFWTIXFWPH-UHFFFAOYSA-N 0.000 description 7
- 229910021529 ammonia Inorganic materials 0.000 description 7
- 239000000243 solution Substances 0.000 description 7
- 229910001935 vanadium oxide Inorganic materials 0.000 description 7
- 229910045601 alloy Inorganic materials 0.000 description 6
- 239000000956 alloy Substances 0.000 description 6
- 230000000694 effects Effects 0.000 description 6
- 239000010954 inorganic particle Substances 0.000 description 6
- 239000004147 Sorbitan trioleate Substances 0.000 description 5
- PRXRUNOAOLTIEF-ADSICKODSA-N Sorbitan trioleate Chemical compound CCCCCCCC\C=C/CCCCCCCC(=O)OC[C@@H](OC(=O)CCCCCCC\C=C/CCCCCCCC)[C@H]1OC[C@H](O)[C@H]1OC(=O)CCCCCCC\C=C/CCCCCCCC PRXRUNOAOLTIEF-ADSICKODSA-N 0.000 description 5
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 5
- 238000001125 extrusion Methods 0.000 description 5
- 235000019337 sorbitan trioleate Nutrition 0.000 description 5
- 229960000391 sorbitan trioleate Drugs 0.000 description 5
- 239000002562 thickening agent Substances 0.000 description 5
- 239000010936 titanium Substances 0.000 description 5
- 229910052719 titanium Inorganic materials 0.000 description 5
- 229910000599 Cr alloy Inorganic materials 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 230000007423 decrease Effects 0.000 description 4
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 4
- 229910052863 mullite Inorganic materials 0.000 description 4
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 3
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 3
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- 239000001768 carboxy methyl cellulose Substances 0.000 description 3
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 3
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 3
- 150000002739 metals Chemical class 0.000 description 3
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 3
- 239000011148 porous material Substances 0.000 description 3
- LNAZSHAWQACDHT-XIYTZBAFSA-N (2r,3r,4s,5r,6s)-4,5-dimethoxy-2-(methoxymethyl)-3-[(2s,3r,4s,5r,6r)-3,4,5-trimethoxy-6-(methoxymethyl)oxan-2-yl]oxy-6-[(2r,3r,4s,5r,6r)-4,5,6-trimethoxy-2-(methoxymethyl)oxan-3-yl]oxyoxane Chemical compound CO[C@@H]1[C@@H](OC)[C@H](OC)[C@@H](COC)O[C@H]1O[C@H]1[C@H](OC)[C@@H](OC)[C@H](O[C@H]2[C@@H]([C@@H](OC)[C@H](OC)O[C@@H]2COC)OC)O[C@@H]1COC LNAZSHAWQACDHT-XIYTZBAFSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 229910052582 BN Inorganic materials 0.000 description 2
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 2
- 239000001856 Ethyl cellulose Substances 0.000 description 2
- ZZSNKZQZMQGXPY-UHFFFAOYSA-N Ethyl cellulose Chemical compound CCOCC1OC(OC)C(OCC)C(OCC)C1OC1C(O)C(O)C(OC)C(CO)O1 ZZSNKZQZMQGXPY-UHFFFAOYSA-N 0.000 description 2
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- 239000002671 adjuvant Substances 0.000 description 2
- 239000011651 chromium Substances 0.000 description 2
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- UPHIPHFJVNKLMR-UHFFFAOYSA-N chromium iron Chemical class [Cr].[Fe] UPHIPHFJVNKLMR-UHFFFAOYSA-N 0.000 description 2
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- 239000010881 fly ash Substances 0.000 description 2
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- 150000004767 nitrides Chemical class 0.000 description 2
- QGLKJKCYBOYXKC-UHFFFAOYSA-N nonaoxidotritungsten Chemical compound O=[W]1(=O)O[W](=O)(=O)O[W](=O)(=O)O1 QGLKJKCYBOYXKC-UHFFFAOYSA-N 0.000 description 2
- 239000011224 oxide ceramic Substances 0.000 description 2
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- 239000012670 alkaline solution Substances 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 238000009924 canning Methods 0.000 description 1
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- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 1
- 229910052753 mercury Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- OGUCKKLSDGRKSH-UHFFFAOYSA-N oxalic acid oxovanadium Chemical compound [V].[O].C(C(=O)O)(=O)O OGUCKKLSDGRKSH-UHFFFAOYSA-N 0.000 description 1
- WIWVNQBYNTWQOW-UHFFFAOYSA-L oxovanadium(2+);diacetate Chemical compound [V+2]=O.CC([O-])=O.CC([O-])=O WIWVNQBYNTWQOW-UHFFFAOYSA-L 0.000 description 1
- SOQBVABWOPYFQZ-UHFFFAOYSA-N oxygen(2-);titanium(4+) Chemical class [O-2].[O-2].[Ti+4] SOQBVABWOPYFQZ-UHFFFAOYSA-N 0.000 description 1
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- CMZUMMUJMWNLFH-UHFFFAOYSA-N sodium metavanadate Chemical compound [Na+].[O-][V](=O)=O CMZUMMUJMWNLFH-UHFFFAOYSA-N 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- GFNGCDBZVSLSFT-UHFFFAOYSA-N titanium vanadium Chemical compound [Ti].[V] GFNGCDBZVSLSFT-UHFFFAOYSA-N 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
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- 239000010937 tungsten Substances 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/16—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J23/24—Chromium, molybdenum or tungsten
- B01J23/30—Tungsten
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
- B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/46—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/632—Organic additives
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- C—CHEMISTRY; METALLURGY
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/71—Ceramic products containing macroscopic reinforcing agents
- C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
- C04B35/80—Fibres, filaments, whiskers, platelets, or the like
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- C—CHEMISTRY; METALLURGY
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
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Description
また、成形機の金属の腐食により、成形されるハニカム構造体にも腐食した金属の付着などの悪影響が及ぶことがあった。
(1)チタン酸化物及び無機バインダを少なくとも含み、長手方向に沿って、一方の端面から他方の端面に延伸する複数のセルが、セル壁によって区画された形状のハニカムユニットを備えたハニカム構造体であって、
少なくとも、硫酸法により合成されたチタン酸化物と、無機バインダと、アルカリ性材料とを混合・混練して得た、pHが5以上の複合材料を前記形状に成形し、焼成してなることを特徴とするハニカム構造体。
前記鱗片状物質は、ガラス、白雲母、アルミナ及びシリカからなる群より選択される一種以上であり、
前記テトラポット状物質は、酸化亜鉛であり、
前記三次元針状物質は、アルミナ、シリカ、炭化ケイ素、シリカアルミナ、ガラス、ワラストナイト、チタン酸カリウム、ホウ酸アルミニウム及びベーマイトからなる群より選択される一種以上であることを特徴とする前記(7)に記載のハニカム構造体。
少なくとも、硫酸法により合成されたチタン酸化物と、無機バインダと、アルカリ性材料とを混合・混練して、pHが5以上の複合材料を得る工程と、
前記複合材料を前記形状に成形した成形体を得る工程と、
前記成形体を焼成する工程と、
を含むことを特徴とするハニカム構造体の製造方法。
また、本発明のハニカム構造体の製造方法は、チタン酸化物及び無機バインダを少なくとも含み、長手方向に沿って、一方の端面から他方の端面に延伸する複数のセルが、セル壁によって区画された形状のハニカムユニットを備えたハニカム構造体の製造方法であって、少なくとも、硫酸法により合成されたチタン酸化物と、無機バインダと、アルカリ性材料とを混合・混練して、pHが5以上の複合材料を得る工程と、前記複合材料を前記形状に成形した成形体を得る工程と、前記成形体を焼成する工程と、を含むことを特徴としている。
このように、酸化硫黄が残留したチタン酸化物を用いた複合材料であっても、pHを5以上に調整して成形機に投入することで成形機の金属の腐食を防止できるのは、例えば、以下の議論から明らかである。
金属の各pHによる状態を示す図として電位−pH図(Pourbaix diagram)が知られている。電位−pH図は、水中における化学種、特に金属の存在領域を電極電位とpHの2次元座標上に図示したものである。電位−pH図は熱力学的データに基づいて計算して作成され、現在ではほとんどの金属の電位−pH図が存在する(例えば、M. Pourbaix, Atlas of Electrochemical Equilibria in Aqueous Solutions, Pergamon Press, London(1966)参照)。電位−pH図は腐食領域図としても使われ、金属種の腐食領域、不感域、不動態を作る不動態域の3つで図示される。また、合金の場合、含有金属種の腐食領域図を重ね合わせることで、一方の金属の腐食領域または不感域に、他方の金属の不動態域が重なった場合、不動態膜が生成し不動態域となることで、金属腐食の進行を抑制できることが知られている。
以上より、酸化硫黄が残留したチタン酸化物を用いた複合材料を成形機に投入した場合であっても、成形機の金属(合金)の電位−pH図に基づき、複合材料を不動態領域となるpHに調整すれば成形機の金属の腐食を防止することができる。
実際に成形機に使用されている合金の電位−pH図を2例示す。図2において、(A)はSUS304の電位−pH図であり、(B)はDPS450R(大同特殊鋼(株)製合金)の電位−pH図である。また、表1に、それぞれの合金の組成を示す。図2より、いずれの場合も、pHが5以上で不動態領域であることが分かる。
このようなハニカム構造体を製造し得る本発明の製造方法について以下に説明する。
また、触媒源として、チタン酸化物の他、バナジウム原料、タングステン原料を含有してもよい。
バナジウム原料としては、メタバナジン酸アンモニウム、メタバナジン酸ナトリウム、メタバナジン酸カリウム、シュウ酸バナジル、酢酸バナジル等が挙げられ、中でも、取り扱いが容易であることから、メタバナジン酸アンモニウムであることが好ましい。メタバナジン酸アンモニウム(NH4VO3)、NH4VO3→V2O5+2NH3+H2Oといった分解反応によって、V2O5を生成し、SCRシステムにおける触媒としての役割を果たす。
いずれも耐熱性が高く、SCRシステムにおける触媒担体として使用した時でも、溶損などがなく、補強材としての効果を持続することができるためである。
焼成時間は、焼成が完結するまでの時間を適宜設定すればよく、例えば、1〜4時間とすることができる。
外周コート層を形成する工程においては、円柱状のハニカムユニット11の両端面を除く外周面に外周コート層用ペーストを塗布する。
酸化チタンを主成分とするチタン/バナジウム系粉末59質量%に、酸化バナジウム源のメタバナジン酸アンモニウム2質量%、有機増粘剤としてメチルセルロース4質量%、無機繊維としてアルミナファイバー3質量%、結合剤としてアルミナバインダー4質量%、成形助剤としてソルビタントリオレエート1質量%、イオン交換水25質量%、アルカリ性材料としてジエタノールアミン2質量%を混合混練して得られた複合材料のpHは5.5になり、スクリュー式押し出し成形機と口金を用いて成形したところ、成形体に変色は無く、成形機金属の腐食は発生しなかった。なお、成形機の金属はDPS450Rであった。
酸化チタンを主成分とするチタン/バナジウム系粉末59質量%に、酸化バナジウム源のメタバナジン酸アンモニウム2質量%、有機増粘剤としてメチルセルロース4質量%、無機繊維としてアルミナファイバー3質量%、結合剤としてアルミナバインダー4質量%、成形助剤としてソルビタントリオレエート1質量%、イオン交換水26質量%、アルカリ性材料としてモノエタノールアミン1質量%を混合混練して得られた複合材料のpHは6.0になり、スクリュー式押し出し成形機と口金を用いて成形したところ、成形体に変色は無く、成形機金属の腐食は発生しなかった。なお、成形機の金属はDPS450Rであった。
酸化チタンを主成分とするチタン/バナジウム系粉末59質量%に、酸化バナジウム源のメタバナジン酸アンモニウム2質量%、有機増粘剤としてメチルセルロース4質量%、無機繊維としてアルミナファイバー3質量%、結合剤としてアルミナバインダー4質量%、成形助剤としてソルビタントリオレエート1質量%、イオン交換水25質量%、アルカリ性材料としてジメチルアミノエタノール2質量%を混合混練して得られた複合材料のpHは5.3になり、スクリュー式押し出し成形機と口金を用いて成形したところ、成形体に変色は無く、成形機金属の腐食は発生しなかった。なお、成形機の金属はDPS450Rであった。
酸化チタンを主成分とするチタン/バナジウム系粉末59質量%に、酸化バナジウム源のメタバナジン酸アンモニウム2質量%、有機増粘剤としてメチルセルロース4質量%、無機繊維としてアルミナファイバー3質量%、結合剤としてアルミナバインダー4質量%、成形助剤としてソルビタントリオレエート1質量%、イオン交換水27質量%を混合混練して得られた複合材料のpHは3.0となり、スクリュー式押し出し成形機と口金を用いて成形したところ、成形体が変色し、成形機金属に腐食が発生した。なお、成形機の金属はDPS450Rであった。
酸化チタンを主成分とするチタン/バナジウム系粉末59質量%に、酸化バナジウム源のメタバナジン酸アンモニウム2質量%、有機増粘剤としてメチルセルロース4質量%、無機繊維としてアルミナファイバー3質量%、結合剤としてアルミナバインダー4質量%、成形助剤としてソルビタントリオレエート1質量%、イオン交換水26.5質量%、アルカリ性材料としてモノエタノールアミン0.5質量%を混合混練して得られた複合材料のpHは4.5となり、スクリュー式押し出し成形機と口金を用いて成形したところ、成形体が変色し、成形機金属に腐食が発生した。なお、成形機の金属はDPS450Rであった。
11、11' ハニカムユニット
11a 貫通孔
11b 隔壁
12 外周コート層
13 接着層
20 保持シール材
30 金属容器
100 排ガス浄化装置
Claims (8)
- チタン酸化物及び無機バインダを少なくとも含み、長手方向に沿って、一方の端面から他方の端面に延伸する複数のセルが、セル壁によって区画された形状のハニカムユニットを備えたハニカム構造体の製造方法であって、
少なくとも、硫酸法により合成されたチタン酸化物と、無機バインダと、アルカリ性材料とを混合・混練して、pHが5以上6以下の複合材料を得る工程と、
前記複合材料を前記形状に成形した成形体を得る工程と、
前記成形体を焼成する工程と、
を含むことを特徴とするハニカム構造体の製造方法。 - 前記アルカリ性材料が、沸点が500℃以下のアルカリ性物質を含む溶液であることを特徴とする請求項1に記載のハニカム構造体の製造方法。
- 前記アルカリ性材料が、ジエタノールアミン、モノエタノールアミン、ジメチルアミノエタノール、およびアンモニア水から選ばれる1種以上、又はジエタノールアミン、モノエタノールアミン、およびジメチルアミノエタノールから選ばれる1種以上を含む溶液であることを特徴とする請求項1又は2に記載のハニカム構造体の製造方法。
- 前記混練物が、さらにバナジウム原料を含むことを特徴とする請求項1又は2に記載のハニカム構造体の製造方法。
- 前記バナジウム原料がメタバナジン酸アンモニウムであることを特徴とする請求項4に記載のハニカム構造体の製造方法。
- 前記無機バインダが、アルミナゾル、シリカゾル、チタニアゾル、水ガラス、セピオライト、アタパルジャイト、ベントナイト及びベーマイトからなる群より選択される一種以上に含まれる固形分であることを特徴とする請求項1〜5のいずれか1項に記載のハニカム構造体の製造方法。
- 前記混練物が、無機繊維、鱗片状物質、テトラポット状物質及び三次元針状物質からなる群より選択される一種以上をさらに含むことを特徴とする請求項1〜6のいずれか1項に記載のハニカム構造体の製造方法。
- 前記無機繊維は、アルミナ、シリカ、炭化ケイ素、シリカアルミナ、ガラス、ワラストナイト、チタン酸カリウム及びホウ酸アルミニウムからなる群より選択される一種以上であり、
前記鱗片状物質は、ガラス、白雲母、アルミナ及びシリカからなる群より選択される一種以上であり、
前記テトラポット状物質は、酸化亜鉛であり、
前記三次元針状物質は、アルミナ、シリカ、炭化ケイ素、シリカアルミナ、ガラス、ワラストナイト、チタン酸カリウム、ホウ酸アルミニウム及びベーマイトからなる群より選択される一種以上であることを特徴とする請求項7に記載のハニカム構造体の製造方法。
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